Systems and methods to provide weld training

ABSTRACT

An example weld training system includes a computing device comprising a display device on a first side and a camera on a second side, the computing device configured to: capture images with the camera; process the captured images to identify a first simulation device as a simulation weld torch and a second simulation device as a simulation workpiece; and display images of a simulated welding operation on the display device of the computing device based on analyzing the captured images to detect indicia of weld performance, the images of the simulated welding operation reflecting the indicia of weld performance; and a mounting device configured to removably hold the computing device to orient the camera of the computing device toward a simulation area.

RELATED APPLICATIONS

The application arises from a continuation application of U.S. patentapplication Ser. No. 15/400,548, filed Jan. 6, 2017, entitled “Systemsand Methods to Provide Weld Training,” and claims priority to U.S.Provisional Patent Application Ser. No. 62/276,290, filed Jan. 8, 2016,entitled “Weld Training Systems and Methods.” The entirety of U.S.Provisional Patent Application Ser. No. 62/276,290 is incorporatedherein by reference.

BACKGROUND

Weld training systems are used to provide training to welders who areunfamiliar with welding and/or with certain aspects of welding.Conventional weld training systems include suites of sensors and/or havevery precise positioning requirements to ensure proper tracking oftraining.

BRIEF SUMMARY

Systems and methods are provided for weld training, substantially asshown in and/or described in connection with at least one of thefigures, as set forth more completely in the claims.

These and other advantages, aspects and novel features of the presentinvention, as well as details of an illustrated embodiment thereof, willbe more fully understood from the following description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagram illustrating an example weld training system inaccordance with aspects of this disclosure.

FIG. 2 is a diagram illustrating another example weld training system inaccordance with aspects of this disclosure.

FIG. 3 is a block diagram of an example implementation of the computingdevice in the weld training systems of FIGS. 1 and/or 2.

FIGS. 4A and 4B are front and rear views of an example tablet computingdevice that may be used to implement the computing device of any ofFIGS. 1-3.

FIG. 5 is a view of the example weld training system of FIG. 1displaying a weld calculator view to set up a training weld.

FIG. 6 is a view of the example weld training system of FIG. 1displaying a weld equipment view to set up a training weld.

FIG. 7 is a view of the example weld training system of FIG. 1displaying a simulated welding view based on processing images capturedby the computing device during a training weld.

FIG. 8 a view of the example weld training system of FIG. 1 displaying aresult of the training weld.

FIG. 9 is a flowchart representative of example machine readableinstructions which may be executed to implement the weld training systemof FIGS. 1 and/or 2 to provide weld training.

FIG. 10 is a flowchart representative of example machine readableinstructions which may be executed to implement the weld training systemof FIGS. 1 and/or 2 to perform a training weld with a computing device.

The figures are not necessarily to scale. Where appropriate, similar oridentical reference numbers are used to refer to similar or identicalcomponents.

DETAILED DESCRIPTION

“Realistic” weld training systems that provide feedback to traineewelders have made great advancements in recent years. However, suchrealistic weld training systems can be very costly. Disclosed examplesare capable of providing low cost or no cost weld training by using areduced-complexity weld training system to teach fundamental concepts ofwelding for which a high degree of realism offered by conventional weldtraining systems is unnecessary.

Disclosed example weld training systems use commonly-available computingdevices containing a display and one or more cameras to simulate theproper setup of welding equipment and simulate weld techniques whileproviding feedback by analyzing images captured using the one or morecameras. In some examples, a weld training system may be implementedusing an application downloaded onto a computing device such as a tabletcomputer or a smartphone, a mounting device to hold the computing devicein a desired orientation, and a real or model welding torch. In someexamples, a real or model welding coupon may also be used as theworkpiece for a training weld. In some other examples, the computingdevice may be used with actual welding equipment, where the computingdevice is positioned between the welder's eyes and the workpiece so asto obstruct the arc from the user's eyes.

Disclosed examples calculate and depict, in real-time and based onanalyzing images captured through the camera, welding events such asspatter, burn back, burn-through, stubbing, and/or any other weldingevents based on measured and calculated performance of the weld. In someexamples the welding events are also determined and based on theappropriateness of the selected weld parameters to the type of weldbeing performed.

Disclosed example weld training systems include a computing devicehaving a display device on a first side and a camera on a second side.The computing device is configured to capture images with the camera andprocess the captured images to identify a first simulation device as asimulation weld torch and a second simulation device as a simulationworkpiece. The computing device is further configured to display imagesof a simulated welding operation on the display device of the computingdevice, based on analyzing the captured images to detect indicia of weldperformance. The images of the simulated welding operation reflect theindicia of weld performance.

Disclosed example non-transitory machine readable storage media storemachine readable instructions may be executed by a processor of acomputing device having a display device on a first side and a camera ona second side. The instructions cause the computing device to captureimages using the camera and process the captured images to identify afirst simulation device as a simulation weld torch and a secondsimulation device as a simulation workpiece. The instructions also causethe processor to display images of a simulated welding operation on thedisplay device based on analyzing the captured images to detect indiciaof weld performance. The images of the simulated welding operationreflect the indicia of weld performance.

Some examples further include a mounting device that holds the computingdevice to orient the camera of the computing device toward a simulationarea. In some examples, the mounting device orients the display deviceof the computing device away from the simulation area. In some examples,the mounting device orients the display device such that a user of thefirst simulation device is facing the simulation area.

In some examples, the display device presents stereoscopic images. Insome such examples, the mounting device includes one or more lenses toprovide a stereoscopic view of the stereoscopic images. In someexamples, the computing device recognizes when the computing device isconnected to the mounting device. In some examples, the mounting deviceincludes a protective housing to prevent damage to the computing devicefrom an actual weld.

In some examples, the processing of the captured images includescalculating a distance between the first simulation device and thesecond simulation device. In some such examples, displaying the imagesof the simulated welding operation is based on the calculated distanceas the indicia of weld performance. In some examples, the computingdevice enables selection of one or more weld variables. In some suchexamples, the computing device depicts welding events including at leastone of spatter, burn back, burn-through, or wire stubbing, based on atleast one of the indicia of weld performance or the one or more weldvariables. In some examples, the computing device enables the selectionof the one or more weld variables with at least one of a weld calculatorview or a weld equipment view.

In some examples, the computing device processes the captured imagesbased on input from a sensor of the computing device. In some suchexamples, the sensor includes at least one of an accelerometer, amagnetometer, a microphone, or an ambient light sensor.

Some examples include a plurality of cameras configured to captureimages substantially simultaneously. In some examples, the computingdevice is a smartphone or a tablet computer. In some examples, thecomputing device processes the captured images without using additionalsensors. In some examples, the camera generates stereoscopic images andthe display device displays the stereoscopic images. In some examples,the indicia of weld performance comprise at least one of aim, travelspeed, work angle, travel angle, or contact tip to work distance.

As used herein, the term “real-time” refers to performance of a processor other action relating to a system in which input data is processedsubstantially immediately (e.g., within milliseconds, as soon aspossible, etc.) so that the result of processing is available virtuallyimmediately as feedback. In this regard, “real-time” is used oncontradistinction to post-processing.

FIG. 1 is a diagram illustrating a weld training system in accordancewith an example implementation of this disclosure. Shown is a computingdevice 106 (e.g., tablet or smartphone) situated in a mounting device108 which holds the screen of the computing device 106 at a position andangle that is comfortable for the welder 102 to view as he performs a(real or simulated) weld on the workpiece 112 (a real metal coupon for areal weld, or a plastic coupon for a simulated weld) using (real ormock) welding torch 110 connected to cables 114.

The mounting device 108 is configured to hold the computing device 106to orient a camera of the computing device 106 toward a simulation area104 (e.g., toward the workpiece 112). The mounting device 108 alsoorients a display device of the computing device 106 away from thesimulation area 104. The mounting device 108 may orient the displaydevice such that a user of the welding torch 110 is facing thesimulation area 104. The computing device 106 may be configured torecognize when the computing device 106 is connected to or mounted inthe mounting device 108. For example, the mounting device 108 maytrigger one or more inputs in the computing device 106 via magnetsand/or capacitively charged elements that are recognized bycorresponding sensors in the computing device 106.

For use with a real weld, the mounting device 108 may comprise aprotective shield (e.g., glass, plastic, or air curtain) to protect thecomputing device from spatter, heat, etc.). Alternatively, the computingdevice 106 may be ruggedized (e.g., by a case which it goes in beforebeing placed in the mount).

The position of the torch 110 and workpiece 112 in three-dimensionalspace is determined from images captured by a camera of the computingdevice 106, images from a camera of the mount (e.g., received by thecomputing device via USB, HDMI, or the like), and/or from output (e.g.,conveyed wirelessly to the computing device 106 from one or more sensorsmounted on the torch 110, workpiece 112, and/or simulation area 104. Forboth a simulated and real weld, this position information may be used tomonitor the welder's technique (e.g., aim, speed, work angle, travelangle, contact tip to work distance, and/or other parameters). For asimulated weld operation, this position information may be used togenerate a simulated arc and/or simulated bead.

As described in more detail below, the welder 102 may input parameterssuch as power source voltage, current, workpiece metal/thickness, and/orthe like via a human machine interface (e.g., touchscreen,pressure-sensitive touchscreen, gestures captured by a forward facingcamera of the computing device 106, and/or the like) of the computingdevice 106. These parameters may be used for monitoring the quality ofthe weld/assessing the technique of the welder 102. For a simulated weldoperation, these parameters may be used for rendering a simulated arcand/or simulated bead. The welder 102 may select a profile for storingthe welder's results of the training session to track progress overtime.

For an actual weld operation, the system may deal with the extremelyhigh contrast resulting from the presence of the weld arc in a varietyof ways. For example, the computing device 106 may be operable toperform a variety of image processing techniques to provide an HDR modesuch that, viewing the screen of the computing device while welding, thewelder 102 can clearly see, simultaneously, the workpiece in closeproximity to the arc (e.g., can see the weld puddle) and relatively farfrom the arc. This is in contrast to viewing the workpiece/arc directlywith protective eyewear because when the arc is on, the eyewear is toodark to see well in areas that are not very brightly lit by the arc. Theexample computing device 106 may serve as an eye protection device inlieu of a welding helmet when placed between the arc of an actual weldand the user's eyes.

In some examples, the computing device 106 presents a three-dimensionalor stereoscopic image. This may either be with the aid of 3D glasses orother lens (which may also be designed to meet requirements asprotective eyewear for welding) or the display may be autostereoscopic.For example, the mounting device 108 may include one or more lenses toprovide a stereoscopic view of stereoscopic images present on thecomputing device 106.

In some examples, the welding system 100 may switch between simulatedwelding mode and real welding mode via an input to a human machineinterface. In this manner, the welder 102 can do a practice run and thenvery quickly switch to a real weld once s/he has a “feel” for the weld.

The mounting device 108 may be such that the computing device 106 iseasily inserted and removed and/or repositioned within the mountingdevice 108. Although the mounting device 108 is shown attached to aworkbench or table in the simulation area 104, it may be easilyremovable and re-mounted elsewhere (e.g., using clamps, magnets, thatcan be manipulated while wearing welding gloves and not requiring anytools). For example, the mounting device 108 may be adapted to permitmounting to different workstations (including different workstations ofdifferent sizes shapes, etc.), to welding equipment (e.g., power source,wire feeder, welding torch, welding robot, etc.), and/or to a workpieceitself.

In some examples, sensor information from the computing device 106(e.g., images from its camera, outputs from its accelerometer,gyroscope, etc.) may be communicated to another computing device, suchas a computing device integrated into the welder's helmet. For example,the welding helmet may comprise a near-to-eye display and data from thecomputing device 106 may be wirelessly communicated to the helmet andpresented on the near-to-eye display of the helmet. Similarly, thedisplay of the helmet may augment the display on the computing device106. For example, the display in the helmet may display parameterscaptured by the accelerometer/gyroscope/etc. of the computing device 106while the display of the computing device is fully allocated topresenting the images captured by its camera. As another example, agraphical user interface for interacting with the computing device maybe presented on a display of the welder's helmet, a wristband, and/orthe like. Similarly, a graphical user interface for interactingwith/controlling, during a real or simulated weld operation, thewelder's helmet, the welder's wristband, a welding power source, wirefeeder, gas cylinder, welding robot, and/or the like may be presented onthe display of the computing device 106.

The computing device 106 may generate a stereoscopic image such that, bychanging the angle at which s/he looks at the display, the welder cansee different angles of the torch/workpiece etc., just as if lookingdirectly at the physical workpiece.

The computing device 106 may include a front facing camera that trackthe welder's head and/or eyes, and may analyze the images captured bythe front facing camera to change the view of the simulated workpiecesuch that the 2 dimensional image moves along with movements of thewelder's eyes and/or head to simulate the welder getting a differentview of the weld operation in progress.

FIG. 2 is a diagram illustrating another example weld training system200. The weld training system 200 of FIG. 2 includes a mounting device202 that holds a computing device 204. Similar to the system 100 of FIG.1, the weld training system 200 positions the computing device 204 suchthat the such that a camera of the computing device 204 is aimed towardthe workpiece 112 and the display device of the computing device 204 isaimed toward the welder 102. However, in contrast with the system 100 ofFIG. 1 where the mounting device 108 is stationary between the welder102 and the workpiece 112, in FIG. 2 the mounting device 202 is aheadset that places the computing device 204 in the line of sight of thewelder 102 such that changes in the welder's viewpoint change the fieldof view of the camera of the computing device 204.

The mounting device 202 may include a headband 206 or other mountingsystem to hold the mounting device 202 and the computing device 204 onthe head of the welder 102. In other examples, the mounting device 202may integrate the computing device 204 into a welding helmet or otherheadwear. In other examples, the mounting device 202 may be attached tothe welder's 102 clothing, helmet, and/or the like.

FIG. 3 is a block diagram of an example implementation of a computingdevice 300. The example computing device 300 of FIG. 3 may be any typeof system that uses a microcontroller or microprocessor to provide oneor more features by executing software, firmware, and/or any othermachine readable code. Example computing devices include laptopcomputers, tablet computers,

The example computing device 300 of FIG. 3 includes a processor 302. Theexample processor 302 may be any specialized or general-purposemicrocontroller, such as a system-on-a-chip (SoC), graphics processingunit, and/or digital signal processor, from any manufacturer. Theprocessor 302 executes machine readable instructions 304 that may bestored locally at the processor (e.g., in an included cache), in arandom access memory 306 (or other volatile memory), in a read onlymemory 308 (or other non-volatile memory such as FLASH memory), and/orin a mass storage device 310. The example mass storage device 310 may bea hard drive, a solid state storage drive, a hybrid drive, a RAID array,and/or any other mass data storage device.

A bus 312 enables communications between the processor 302, the RAM 306,the ROM 308, the mass storage device 310, a network interface 314,and/or an input/output interface 316.

The example network interface 314 includes hardware, firmware, and/orsoftware to connect the computing device 300 to a communications network318 such as the Internet. For example, the network interface 314 mayinclude IEEE 802.X-compliant wireless and/or wired communicationshardware for transmitting and/or receiving communications.

The example I/O interface 316 of FIG. 3 includes hardware, firmware,and/or software to connect one or more input/output devices 320 to theprocessor 302 for providing input to the processor 302 and/or providingoutput from the processor 302. For example, the I/O interface 316 mayinclude a graphics processing unit for interfacing with a displaydevice, a universal serial bus port for interfacing with one or moreUSB-compliant devices, a FireWire, a field bus, and/or any other type ofinterface. The example computing device 300 of FIG. 3 includes one ormore camera(s) 324 as an input device and one or more display device(s)326 as an output device. The camera(s) 324 may be capable of capturingstereoscopic images and/or the display device(s) 326 may be capable ofdisplaying stereoscopic images.

The I/O device(s) 320 may also include a keyboard, a keypad, a mouse, atrackball, a pointing device, a microphone, an audio speaker, an opticalmedia drive, a multi-touch touch screen, a gesture recognitioninterface, a magnetic media drive, and/or any other type of input and/oroutput device.

The example computing device 300 may access a non-transitory machinereadable medium 322 via the I/O interface 316 and/or the I/O device(s)320. Examples of the machine readable medium 322 of FIG. 3 includeoptical discs (e.g., compact discs (CDs), digital versatile/video discs(DVDs), Blu-ray discs, etc.), magnetic media (e.g., floppy disks),portable storage media (e.g., portable flash drives, secure digital (SD)cards, etc.), and/or any other type of removable and/or installedmachine readable media.

Consistent with embedded systems, one or more of the processor 302, therandom access memory 306, the read-only memory 308, the mass storagedevice 310, the bus 312, the network interface 314, and/or the I/Ointerface 316 may be implemented in a single package.

FIGS. 4A and 4B are front and rear views of an example tablet computingdevice 400 that may be used to implement the computing device of any ofFIGS. 1-3. As illustrated in FIG. 4A, the tablet computing device 400includes a display device 402 on a first side of the tablet computingdevice 400. As illustrated in FIG. 4B, the tablet computing device 400includes one or more camera(s) 404 on a second side of the tabletcomputing device 404 opposite the first side shown in FIG. 4A. In thismanner, the computing device 400 may be positioned in the field of viewof the welder 102 to both capture images of the welding scene with thecamera(s) 404 and display the resulting images on the display device 402in to the welder 102 in real time.

FIG. 5 is a view of the example weld training system 100 of FIG. 1displaying a weld calculator view 502 to set up a training weld. Theweld training system 100 may display the weld calculator view 502 toenable a welder to experiment with weld calculator recommendations fordifferent combinations of physical workpiece characteristics. The weldcalculator view 502 includes a button 504 to change to a weld equipmentview (illustrated in FIG. 6) and a button 506 to begin a training weld(illustrated in FIG. 7).

The weld calculator view 502 includes characteristics of the jointand/or the weld, such as values for input parameters including, but notlimited to, a desired fillet size, a desired penetration depth, apenetration profile, a bead width, a bevel width, a gap width, a jointlength, and/or a bevel angle. The weld calculator view 502 mayadditionally or alternatively include inputs for wire type, wire feedspeed, shielding gas type, spin or weave pattern, and/or travel speed.In some examples, the weld calculator view 502 may permit the welder torequest a recommendation for weld variables such as, but are not limitedto, a weld process 96, a power source voltage setting, a power sourcecurrent setting, a power source frequency, a polarity, and/or anoperation mode (e.g., constant current CC, constant voltage CV, orpulse).

Example systems and methods that may be used to implement the weldcalculator view 502 of FIG. 5 are disclosed in Albrecht, U.S. PatentPublication No. 2015/0122781. The entirety of U.S. Patent PublicationNo. 2015/0122781 is incorporated herein by reference.

FIG. 6 is a view of the example weld training system 100 of FIG. 1displaying a weld equipment view 602 to set up a training weld. Theexample weld equipment view 602 presents a simulated view of the userinterface of welding equipment in a manner that is representative of howactual welding equipment would appear to the welder. The weld equipmentview 602 presents a front view of the user interface 604 of an examplewelder. In some examples, the weld equipment view 602 may change basedon a selection of a particular model of welding equipment selected. Inthis manner, a welder may use the weld training system 100 to becomefamiliar with a particular piece of welding equipment and/or to becomefamiliar with welding equipment in general.

The weld equipment view 602 includes a process input 606 to select awelding process (e.g., flux cored, MIG, TIG, stick, etc.), an electrodeinput 608 to select a wire/rod/tungsten type and/or size, a thicknessinput 610 to select a material thickness, a voltage/current dial 612, awire feed speed dial 614, and an auto-set toggle 616. The weld equipmentview 602 also includes a display 618 to output information is theinformation could be shown on welding equipment. While example inputsand outputs are shown for the weld equipment view 602 of FIG. 6, one ormore of the inputs and/or outputs may be combined, replaced, divided,and/or otherwise modified, and/or additional inputs and/or outputs maybe provided. In some examples, one or more of the inputs and/or outputsmay be softkeys or other software-defined inputs that control differentfunctions depending on the particular context.

The weld equipment view 602 includes a button 620 to change to the weldcalculator view 502 described above with reference to FIG. 5, and abutton 622 to begin a training weld.

FIG. 7 is a view of the example weld training system of FIG. 1displaying a simulated welding view 702 based on processing imagescaptured by the computing device 106 during a training weld. Forexample, during the training weld the welder 102 attempts to perform awelding operation using the real or simulated welding torch 110 over theworkpiece 112, which may include attempting to achieve a target travelspeed and/or a target contact tip to work distance.

During the training weld, the computing device 106 captures images withthe camera of the computing device 106 (e.g., the camera(s) 324, 404 ofFIGS. 3 and/or 4B), processes the captured images to identify a firstsimulation device (e.g., the welding torch 110) as a simulation weldtorch and a second simulation device (e.g., the workpiece 112) as asimulation workpiece, and displays images of a simulated weldingoperation on the display device of the computing device 106 (e.g., thedisplay device(s) 326, 402 of FIGS. 3 and/or 4A) based on analyzing thecaptured images to detect indicia of weld performance. The images of thesimulated welding operation displayed on the display device in thesimulated welding view reflect the indicia of weld performance.

As shown in FIG. 7, there is no arc or weld bead being created by thewelding torch 110 and the workpiece 112. Instead, the computing device106 captures images of the welding torch 110 and the workpiece 112,analyzes the images (e.g., in real time) to determine the indicia ofweld performance, and calculates or simulates the weld performance inreal-time based on the image processing. The simulated welding view 702displays images 704 of a simulated welding operation on the displaydevice of the computing device 106. In the example of FIG. 7, the images704 include the hand of the welder 102, the welding torch 110, and theworkpiece 112 as captured by the camera(s). When performing a simulatedweld (instead of a live weld), the images 704 also include a simulatedwelding arc 706, a simulated weld bead 708, and/or a simulated weldpuddle 710 calculated in real-time by the computing device 106 andoverlaid on the images captured by the camera(s).

Processing of captured images may include calculating a distance betweenthe simulation welding torch 110 and the simulation workpiece 112 and/orthe displaying of the images of the simulated welding operation is basedon the calculated distance as the indicia of weld performance.

The simulated welding view 702 may depict welding events such asspatter, burn back, burn-through, and/or wire stubbing, based onanalyzing the images captured by the camera(s) to determine the user'swelding performance and/or based on weld variables.

In some examples, one or more of the sensors of the computing device 106may be used as part of the analysis. For example, one or more of anaccelerometer, a magnetometer, a microphone, or an ambient light sensorof the computing device 106 may be used to determine information aboutfrom the training weld or the computing device 106. In other examples,the computing device 106 does not use any sensors other than thecamera(s).

FIG. 8 illustrates a view 802 of the example weld training system 100 ofFIG. 1 displaying a result of the training weld. The example view 802includes an image 804 of the simulated weld calculated during thetraining weld, and a graph 806 of one or more weld variables and/orperformance scores. The view 802 may present and/or highlight calculatedor simulated defects based on the weld performance during the trainingweld.

The example welding parameter is graphed in FIG. 8 is presented inrelation to the calculated weld bead 708 on the workpiece 112. Asillustrated in the graph 806, the welding variable resides betweenmaximum and minimum limit values Accordingly, no defects are displayedor anticipated in the weld bead 708 in the view 802 of FIG. 8.

The example view 802 includes a button 808 to enable the welder 102 toreturn to the weld calculator view 502 of FIG. 5 to adjust the weldsettings, a button 810 to enable the welder 102 to return to the weldequipment view 602 of FIG. 6 to adjust the weld settings, and/or abutton 812 to retry to the training weld with the same weld settings.

FIG. 9 is a flowchart representative of example machine readableinstructions 900 which may be executed to implement the weld trainingsystems 100, 200 of FIGS. 1 and/or 2 to provide weld training. Forexample, the instructions 900 may be stored in one or more of thestorage devices 306, 308, 310 and/or executed on the processor 302 ofFIG. 3.

At block 902, an application (or “app) is opened on the computing device106. For example, the welder 102 may select an app and/or the computingdevice 106 may recognize that the computing device 106 has been attachedto the mounting device 108 and automatically open the app in response.

At block 904, the computing device 106 reads inputs relating to a weldtraining configuration. For example, the computing device 106 may readone or more sensors, such as an accelerometer, to determine whether thecomputing device 106 is oriented correctly for performing weld training.A correct orientation may be useful to ensure that a training weld iscaptured and displayed to the welder 102.

At block 906, the computing device 106 determines whether the computingdevice 106 is in a physical configuration (e.g., orientation) for weldtraining. A physical orientation for weld training may include beingattached to the mounting device 108 and/or being oriented at a correctangle relative to gravity. If the computing device 106 is not in aphysical configuration for weld training (block 906), at block 908 thecomputing device 106 determines whether the computing device 106 hasbeen manually set for a weld training configuration. For example, thewelder 102 may instruct the computing device 106 to enter a weldtraining mode even if the computing device 106 is not in a particularorientation. If the computing device 106 has not been manually set for aweld training configuration (block 908), control returns to block 904.

If the computing device 106 is in a physical configuration for weldtraining (block 906) or the computing device 106 has been manually setfor a weld training configuration (block 908), at block 910 thecomputing device 106 guides the user through weld setup on the computingdevice 106. For example, the computing device 106 may present the weldcalculator view 502 and/or the weld equipment view 602 of FIGS. 5 and/or6 to enable the user to set up parameters for a training weld.

At block 912, the computing device 106 performs weld training analysisand presentation. For example, while the welder 102 performs a trainingweld, the computing device 106 capture images with camera(s) of thecomputing device 106, processes the captured images to identify a firstsimulation device (e.g., the weld torch 110) as a simulation weld torchand a second simulation device (e.g., the workpiece 112) as a simulationworkpiece, and displays images of a simulated welding operation on thedisplay device (e.g., the view 702 of FIG. 7) of the computing device106 based on analyzing the captured images (e.g., in real-time) todetect indicia of weld performance, where the images of the simulatedwelding operation reflect the indicia of weld performance Exampleinstructions to implement block 912 are described below with referenceto FIG. 10.

At block 914, after the training weld is completed, the computing device106 presents results of the training weld (e.g., in the view 802 of FIG.8). In some examples, the computing device 106 may identify suggestionsor hints to the welder 102 for improving the weld based on the selectedweld parameters and/or the welder's performance during the trainingweld. Example suggestions may include changing one or more of the weldparameters and/or changing one or more aspects of the welder'stechnique.

At block 916, the computing device 106 determines whether the weldconfiguration is to be modified, such as in response to a selection ofthe buttons 808, 810 to return to the weld calculator view 502 and/orthe weld equipment view 602. If the weld configuration is to be modified(block 916), control returns to block 910.

If the weld configuration is not to be modified (block 916), at block918 the computing device 106 determines whether another training weld isto be performed with the same settings. If another training weld is tobe performed (block 918), control returns to block 912. If no furthertraining welds are to be performed (block 918), the example instructions900 may end.

FIG. 10 is a flowchart representative of example machine readableinstructions 1000 which may be executed to implement the weld trainingsystems 100, 200 of FIGS. 1 and/or 2 to perform a training weld with acomputing device. The instructions 1000 of FIG. 10 may be executed toimplement block 912 of FIG. 9 to perform a training weld with thecomputing device 106. The instructions 1000 may begin, for example,after a user accepts a set of weld parameters in block 910.

At block 1002, the computing device 106 captures images with one or morecamera(s) of the computing device 106. For example, the computing device106 may capture the images using the camera(s) 322, 404 of FIGS. 3and/or 4B.

At block 1004, the computing device 106 processes the captured images toidentify a first simulation device as a simulation weld torch. In someexamples, the computing device 106 may use image processing techniquesto identify the welding torch 110 as a device held by the user's handand/or as having distinct markings identifying the device as a weldingtorch.

At block 1006, the computing device 106 processes the captured images toidentify a second simulation device as a simulation workpiece. Forexample, the computing device 106 may use image processing techniques toidentify the workpiece 112 as having a particular shape, as an objectdistinct from a background or other surface on which the object isresting, and/or as having distinct markings identifying the device as aworkpiece.

At block 1008, the computing device 106 determines whether sensor datais available that is relevant to the training weld. For example,relevant sensor data may include accelerometer and/or gyroscope data todetermine an orientation and/or movement of the computing device 106(e.g., if the computing device is mounted to the headwear of the welder102). If relevant sensor data is not available (block 1008), at block1010 the computing device 106 measures one or more indicia of weldingperformance based on the images captured by the camera(s). For example,the computing device 106 may calculate indicia such as aim, speed, workangle, travel angle, and/or contact tip to work distance using theimages.

On the other hand, if relevant sensor data is available (block 1008), atblock 1012 the computing device 106 measures one or more indicia ofwelding performance based on the images captured by the camera(s) andbased on the sensor data.

After measuring the one or more indicia at block 1010 or block 1012, atblock 1014 the computing device 106 calculates/simulates weldperformance based on the measured one or more indicia. For example, thecomputing device 106 may use a model to calculate a weld result usingthe measured indicia, such as aim, travel speed, work angle, travelangle, and/or contact tip to work distance, and/or the selected weldparameters as inputs to the model.

At block 1016, the computing device 106 displays images of a simulatedwelding operation on the display device (e.g., the display devices 326,402 of FIGS. 3 and/or 4A). The images of the simulated welding operationare determined in real-time during the training weld based on thecalculated or simulated weld performance. Thus, the example computingdevice 106 may depict spatter, flares, stubbing, and/or any otherwelding events based on the measured and calculated performance, andbased on the appropriateness of the selected weld parameters to the typeof weld being performed.

At block 1018, the computing device 106 determines whether the trainingweld is complete. If the training weld is not complete (block 1018),control returns to block 1008 to continue monitoring the training weld.When the training weld is complete (block 1018), the exampleinstructions 1000 end and control returns to block 914 of FIG. 9.

As utilized herein the terms “circuits” and “circuitry” refer tophysical electronic components (i.e. hardware) and any software and/orfirmware (“code”) which may configure the hardware, be executed by thehardware, and or otherwise be associated with the hardware. As usedherein, for example, a particular processor and memory may comprise afirst “circuit” when executing a first one or more lines of code and maycomprise a second “circuit” when executing a second one or more lines ofcode. As utilized herein, “and/or” means any one or more of the items inthe list joined by “and/or”. As an example, “x and/or y” means anyelement of the three-element set {(x), (y), (x, y)}. In other words, “xand/or y” means “one or both of x and y”. As another example, “x, y,and/or z” means any element of the seven-element set {(x), (y), (z), (x,y), (x, z), (y, z), (x, y, z)}. In other words, “x, y and/or z” means“one or more of x, y and z”. As utilized herein, the term “exemplary”means serving as a non-limiting example, instance, or illustration. Asutilized herein, the terms “e.g.,” and “for example” set off lists ofone or more non-limiting examples, instances, or illustrations. Asutilized herein, circuitry is “operable” to perform a function wheneverthe circuitry comprises the necessary hardware and code (if any isnecessary) to perform the function, regardless of whether performance ofthe function is disabled or not enabled (e.g., by a user-configurablesetting, factory trim, etc.).

The present method and/or system may be realized in hardware, software,or a combination of hardware and software. The present methods and/orsystems may be realized in a centralized fashion in at least onecomputing system, or in a distributed fashion where different elementsare spread across several interconnected computing systems. Any kind ofcomputing system or other apparatus adapted for carrying out the methodsdescribed herein is suited. A typical combination of hardware andsoftware may be a general-purpose computing system with a program orother code that, when being loaded and executed, controls the computingsystem such that it carries out the methods described herein. Anothertypical implementation may comprise an application specific integratedcircuit or chip. Some implementations may comprise a non-transitorymachine-readable (e.g., computer readable) medium (e.g., FLASH drive,optical disk, magnetic storage disk, or the like) having stored thereonone or more lines of code executable by a machine, thereby causing themachine to perform processes as described herein.

While the present method and/or system has been described with referenceto certain implementations, it will be understood by those skilled inthe art that various changes may be made and equivalents may besubstituted without departing from the scope of the present methodand/or system. In addition, many modifications may be made to adapt aparticular situation or material to the teachings of the presentdisclosure without departing from its scope. Therefore, it is intendedthat the present method and/or system not be limited to the particularimplementations disclosed, but that the present method and/or systemwill include all implementations falling within the scope of theappended claims.

What is claimed is:
 1. A weld training system, comprising: a computingdevice comprising a display device on a first side and a camera on asecond side, the computing device configured to: capture images with thecamera; process the captured images to identify a first simulationdevice as a simulation weld torch and a second simulation device as asimulation workpiece; and display images of a simulated weldingoperation on the display device of the computing device based onanalyzing the captured images to detect indicia of weld performance, theimages of the simulated welding operation reflecting the indicia of weldperformance; and a mounting device configured to removably hold thecomputing device to orient the camera of the computing device toward asimulation area.
 2. The weld training system as defined in claim 1,wherein the mounting device is configured to orient the display deviceof the computing device away from the simulation area.
 3. The weldtraining system as defined in claim 1, wherein the mounting device isconfigured to orient the display device such that a user of the firstsimulation device is facing the simulation area.
 4. A weld trainingsystem, comprising: a computing device comprising a display device on afirst side and a camera on a second side, the computing deviceconfigured to: capture images with the camera; process the capturedimages to identify a first simulation device as a simulation weld torchand a second simulation device as a simulation workpiece; and displayimages of a simulated welding operation on the display device of thecomputing device based on analyzing the captured images to detectindicia of weld performance, the images of the simulated weldingoperation reflecting the indicia of weld performance; and a mountingdevice configured to removably hold the computing device to orient thecamera of the computing device toward a simulation area, wherein thecomputing device is configured to recognize when the computing device isconnected to the mounting device.
 5. The weld training system as definedin claim 1, wherein the mounting device comprises a protective housingto prevent damage to the computing device from an actual weld.
 6. Theweld training system as defined in claim 1, wherein the processing ofthe captured images comprises calculating a distance between the firstsimulation device and the second simulation device.
 7. The weld trainingsystem as defined in claim 6, wherein the displaying of the images ofthe simulated welding operation is based on the calculated distance asthe indicia of weld performance.
 8. The weld training system as definedin claim 1, wherein the computing device is configured to enableselection of one or more weld variables.
 9. The weld training system asdefined in claim 8, wherein the computing device is configured to depictwelding events including at least one of spatter, burn back,burn-through, or wire stubbing, based on at least one of the indicia ofweld performance or the one or more weld variables.
 10. The weldtraining system as defined in claim 8, wherein the computing device isconfigured to enable the selection of the one or more weld variableswith at least one of a weld calculator view or a weld equipment view.11. The weld training system as defined in claim 1, wherein thecomputing device is configured to process the captured images based oninput from a sensor of the computing device.
 12. The weld trainingsystem as defined in claim 11, wherein the sensor comprises at least oneof an accelerometer, a magnetometer, a microphone, or an ambient lightsensor.
 13. The weld training system as defined in claim 1, furthercomprising a plurality of cameras configured to capture imagessubstantially simultaneously.
 14. The weld training system as defined inclaim 1, wherein the computing device is a smartphone or a tabletcomputer.
 15. The weld training system as defined in claim 1, whereinthe computing device is configured to process the captured imageswithout using additional sensors.
 16. The weld training system asdefined in claim 1, wherein the camera is configured to generatestereoscopic images and the display device is configured to display thestereoscopic images.
 17. The weld training system as defined in claim 1,wherein the indicia of weld performance comprise at least one of aim,travel speed, work angle, travel angle, or contact tip to work distance.18. A weld training system, comprising: a computing device comprising adisplay device on a first side and a camera on a second side, thecomputing device comprising a processor configured to: capture imageswith the camera; process the captured images to identify a firstsimulation device as a simulation weld torch and a second simulationdevice as a simulation workpiece; and display images of a simulatedwelding operation on the display device of the computing device based onanalyzing the captured images to detect indicia of weld performance, theimages of the simulated welding operation reflecting the indicia of weldperformance, wherein the computing device is one of a smartphone or atablet computer; and a mounting device configured to removably hold thecomputing device to orient the camera of the computing device toward asimulation area.
 19. The weld training system as defined in claim 18,wherein the computing device comprises a touchscreen, and the processoris configured to receive input parameters via the touchscreen.